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Repair Center  How to Replace the Spill Valve on a Karcher Pressure Washer

Why Read This Article?

  • Fix your pressure washer's pressure problems.
  • Save money by repairing your lawn equipment yourself.
  • Learn to break down the pump on a pressure washer.

Article Breakdown

Repair Information:
Difficulty: Easy Duration: 30-45 minutes Frequency: As needed
Removing the Pump:
1. Remove bolts that hold the pump to the pressure washer.
2. Cut the detergent line.
3. Separate the pump from the engine.
Replacing the Spill Valve:
1. Remove the button cap.
2. Remove the thermal release valve.
3. Remove the spill valve.
4. Lubricate the new spill valve.
5. Install the new spill valve.
6. Reinstall the thermal release valve.
7. Fasten the button cap.
Reinstalling the Pump:
1. Cut off the old detergent hose.
2. Install the pump on the washer engine.
3. Fasten the detergent hose.

Video

Tools & Materials

  • Flat-head screwdriver
  • Torx bits (specifically for Karcher: Torx 30)
  • Allen wrench ratchets
  • Wire cutters or a box cutter
  • A good set of grippy needle-nose pliers

How to Replace the Spill Valve on a Karcher Pressure Washer

August 9, 2011
This article will help you fix a common problem with pressure washers: the spill valve. This part is responsible for most of the pressure-related problems you will have with pressure washers.
When your pressure washer loses pressure, it probably means you have a bad spill valve. Also known as an unloader valve, this part allows water to recirculate in the pump when you're not spraying water and is responsible for most of the pressure-related problems with your pressure washer.

For this repair we used a Karcher pressure washer, but the repair will be similar with most pressure washer models. Before beginning this repair you will want to be sure you have a set of Torx bits and Allen wrenches or ratchets as many pressure washers incorporate these types of bolts and screws. Remember to use eReplacementParts.com's Karcher parts search feature to ensure you get the right parts for your Karcher pressure washer.   Removing the Pump You can access the spill valve without removing the pump from the pressure washer, but you may find it more difficult to leave the pump on because the pressure washer frame doesn't leave a lot of room for the repair. You will find it easier to remove the pump from the pressure washer before beginning the spill valve repair.

1. Remove the bolts that hold the pump to the pressure washer

Remove the four bolts that hold the pump to the pressure washer.

2. Cut the detergent line

Use your box or wire cutters to cut the detergent line where it attaches to the pump.

3. Separate the pump from the engine

Now you can remove the pump from the pressure washer engine. Just slide it out and away from the engine.

[Back to Top]   Replacing the Spill Valve Now that you've removed the pump, you can remove the spill valve without the pressure washer frame getting in your way.

1. Remove the button cap

Use a flat-head screwdriver to pry up the button cap. Then remove the black thermal valve cap.

2. Remove the thermal release valve

Remove the two screws that hold the thermal release valve to the pump. These screws may require Torx 30 bits, depending on the pressure washer. Karcher pressure washers use Torx bits to fasten the thermal release valve.

Slowly remove the thermal release valve--a spring is hiding beneath it.

Remove the thermal release valve spring.

3. Remove the spill valve

Now you can remove the spill valve. You will need a good set of needle-nose pliers to grip the tab on the valve.

Hold the pump assembly firmly, and pull the spill valve out of the pump. It is normal for this to take a good bit of force.

4. Lubricate the new spill valve

Before installing your new valve, you need to lubricate the top o-ring (the o-ring is green on Karcher spill valves). Do not lubricate the bottom o-ring--it holds the valve in place.

5. Install the new spill valve

Use your pliers to grasp the tab on the new valve and place it back into the pump.

6. Reinstall the thermal release valve

Replace the thermal release valve spring.

Now fasten the release valve back into place with the Torx screws.

7. Fasten the button cap

Set the thermal release valve cap into place and use a screwdriver to pound the button cap back onto the assembly.

[Back to Top]   Reinstalling the Pump Now that your new spill valve is installed, you can reattach the pump to the pressure washer engine.

1. Cut off the old detergent hose

Cut off the leftover piece of detergent line on the pump nipple.

2. Install the pump on the washer engine

Slide the pump into place on the engine and begin tightening the bolts. Once the bolts become snug, tighten each one a little bit at a time so the pump creates a solid seal with the engine.

3. Fasten the detergent hose

Now all you have to do is slide the detergent line onto the pump nipple.

[Back to Top]   Conclusion Replacing the spill valve on your pressure washer is an easy repair that you can do in under an hour. If your pressure washer has lost pressure, this is the part that's most likely responsible. With a basic tool kit you can remove the pump and gain access to the valve--and replacing it is a breeze. With our lawn equipment parts finder, you can rest assured that you'll get the right spill valve and any other pressure washer parts you may need.And since our huge inventory of in-stock parts ship within 24 hours, you can know you'll get the right part fast.   [Back to Top]
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